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<p>Laser powder bed fusion (LPBF) is a widely used additive manufacturing technique for fabrication of near-net-shaped components that offer design flexibility, rapid solidification characteristics, and creates a high strength material with unique microstructure. This work systematically investigates the effect of post-processing heat treatment on the microstructure and mechanical properties of AlSi10Mg alloy fabricated through LPBF over a wide range of temperatures and holding times. Microstructures were characterized by optical microscopy, scanning electron microscopy, and electron backscatter diffraction, while mechanical response was evaluated through hardness and uniaxial tensile testing. AlSi10Mg alloy in the as-built condition exhibits a cellular microstructure, supersaturated α-Al cells surrounded by a Si-rich eutectic network, and nanoscale silicon precipitates, typical microstructural characteristics of rapidly solidified LPBF material. Heat treatments at lower temperatures and shorter time durations resulted in minimal modification of the silicon network, while heat treatment at relatively higher temperatures and longer holding times led to progressive thickening, fragmentation, and eventual globularization of the Si phase. These microstructural changes were accompanied by a gradual reduction in strength and an improvement in ductility, reflecting the transition from a network-dominated strengthening regime to a more recovery- and coarsening-controlled response. In the as-built state, Si in solid solution and fine cellular Si network caused strengthening, however following&#xa0;heat treatment,&#xa0;grain/cell boundary effects, dispersion , and precipitation became&#xa0;dominant hardening mechanismst. Among the investigated conditions, AlSi10Mg directly aged at 245&#xa0;°C for 30&#xa0;min provided the most favorable balance between strength and ductility, consistent with partial stress relief and preservation of the Si cellular network.</p>

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Role of Si Network Evolution in Governing Mechanical Properties of Heat-Treated Laser Powder Bed Fusion AlSi10Mg Alloy

  • 期刊论文

  • 发表日期：

    2026年4月25日

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  • Anil Kumar Ramavajjala,
  • Rajesh K. Khatirkar,
  • C. Joshi,
  • R. N. Chouhan,
  • A. Agnihotri

摘要

Laser powder bed fusion (LPBF) is a widely used additive manufacturing technique for fabrication of near-net-shaped components that offer design flexibility, rapid solidification characteristics, and creates a high strength material with unique microstructure. This work systematically investigates the effect of post-processing heat treatment on the microstructure and mechanical properties of AlSi10Mg alloy fabricated through LPBF over a wide range of temperatures and holding times. Microstructures were characterized by optical microscopy, scanning electron microscopy, and electron backscatter diffraction, while mechanical response was evaluated through hardness and uniaxial tensile testing. AlSi10Mg alloy in the as-built condition exhibits a cellular microstructure, supersaturated α-Al cells surrounded by a Si-rich eutectic network, and nanoscale silicon precipitates, typical microstructural characteristics of rapidly solidified LPBF material. Heat treatments at lower temperatures and shorter time durations resulted in minimal modification of the silicon network, while heat treatment at relatively higher temperatures and longer holding times led to progressive thickening, fragmentation, and eventual globularization of the Si phase. These microstructural changes were accompanied by a gradual reduction in strength and an improvement in ductility, reflecting the transition from a network-dominated strengthening regime to a more recovery- and coarsening-controlled response. In the as-built state, Si in solid solution and fine cellular Si network caused strengthening, however following heat treatment, grain/cell boundary effects, dispersion , and precipitation became dominant hardening mechanismst. Among the investigated conditions, AlSi10Mg directly aged at 245 °C for 30 min provided the most favorable balance between strength and ductility, consistent with partial stress relief and preservation of the Si cellular network.